IRJET- Development of Al-Sic MMC by Bottom Pouring Stir Casting and Parametric Analysis on EDM

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 05 Issue: 04 | Apr-2018 www.irjet.net p-ISSN: 2395-0072
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Development of Al-SiC MMC by bottom pouring stir casting
and parametric analysis on EDM
Jay A. Patel1, Chirag P. Patel2
1Post Graduate Scholar, Department of Advanced Manufacturing Systems, U.V. Patel College of Engineering,
Ganpat University, Mehsana, Gujarat, India
2Associate Professor, Mechanical Engineering Department, , U.V. Patel College of Engineering,
Ganpat University, Mehsana, Gujarat, India.
--------------------------------------------------------------------------***----------------------------------------------------------------------------
Abstract - Development of metal matrix composite (MMC)
to study about the microstructures, hardness of as cast silicon
carbide (SiC) reinforced with aluminum metal matrix
composite. Aluminum (HE 30) and Silicon carbide reinforced
particles metal-matrix composites (MMCs) were fabricated by
bottom pouring stir casting technique. The MMC are prepared
with varying the reinforced particles of SiC by weight fraction
ranging from 10,15,20 in percentage. The average reinforced
particles sizes of SiC is 400 mesh. Hardness for all cast
composite and microstructure of Al-15% SiC composite are
analyzed.
Non-conventional processes such as electrical discharge
machining (EDM) could be one of the best suited methods to
machine such composites. Prepared specimens of Al-SiC MMC
are used as work piece (anode), copper electrodes are used as
tool (cathode) and kerosene oil is used as the dielectric fluid.
Four machining parameters such as discharge current I
(5,12,20 Amp), pulse on time (100,500,1000 µs), gap voltage
Vg (10,20,30 Volts) and material property weight fraction of
SiCp (10,15,20)and responses like material removal rate
(MRR), tool wear rate (TWR), and surface roughness (Ra) are
considered in this study. Taguchi method is adopted to design
the experimental plan. The influence of each parameter on the
responses is established using analysis of variances (ANOVA).
Key Words: Metal matrix composite, stir casting, hardness,
Microstructure, Electrical discharge machining, Anova
1. INTRODUCTION
Composite materials play an important role in the field of
engineering as well as advance manufacturing in response
to unprecedented demands from technology due to rapidly
advancing activities in aircrafts, aerospace and automotive
industries.[1]
There are two major reasons for the current interest in
composite materials. The first is simply the need for
materials that will outperform the traditional monolithic
materials. The second and more important in the long run is
that composite offer engineers the opportunity to design
totally new materials with the precise combination of
properties needed for specific tasks.[2]
1.1 Al-SiC MMC
Aluminum is used widely as a structural material especially
in the aerospace industry because of its light weight
properties. Its low strength and low melting point of
aluminum were always a problem. An effective method of
solving these problems is to use a reinforced element such
as SiC particles and whiskers. The main objective of using
silicon carbide reinforced aluminum alloy composite system
for advanced structural components to replace the existing
super alloys.
1.2 Stir casting process
In a stir casting process, the reinforcing phases are
distributed into molten matrix by mechanical stirring. Stir
casting of metal matrix composites was initiated in 1968,
when S. Ray introduced alumina particles into aluminum
melt by stirring molten aluminum alloys containing the
ceramic powders. Mechanical stirring in the furnace is a key
element of this process. The resultant molten alloy, with
ceramic particles, can then be used for die casting,
permanent mold casting, or sand casting as shown in figure
1.
Fig - 1: Process of Stir Casting [3]

Among all the well-established metal matrix composite
fabrication methods, stir casting is the most economical. For
that reason, stir casting is currently the most popular
commercial method of producing aluminum based
composites. [4]
Fig - 2: Schematic view of setup for Fabrication of
composite [5]
1. Motor 2. Shaft
3. Molten aluminum 4. Thermocouple
5. Particle injection
chamber
6. Insulation hard
board
7. Furnace 8. Graphite crucible
2. Literature review on development of MMC
K.Umanatha,S.T.Selvamanib,K. PalanikumarKc and
D.Niranjanavarmaa et. al. [7] Aluminium alloy (AA6061)
hybrid metal matrix composites (HMMCs) with 5 to 25%
vol. fractions of Silicon Carbide and Aluminium Oxide
reinforcements were created by stir casting technique.
metal to metal wear behavior of hybrid composite and that
of un-reinforced alloy was investigated by pin-on-disc wear
testing machine. The optical micrographs of hybrid
composites produced by stir casting methodology shows
that the allocation of SiC and Al particulates in MMC is
homogeneous. The porosity of the test material increases
with increase in vol. fraction of reinforced particles.
A. Ourdjini, K.C. Chew, B.T. Khoo et. al. [8] Isothermal
holding of A356 Al alloy reinforced with 20 wt. % of SiC
And examination on microstructure for settling of particles
during liquid processing of composite. and get in results,
settling measurements during isothermal holding show that
the SiC particles settle at much lower rates than predicted
by isothermal model. Qualitative examination of the settling
phenomenon shows that composites reinforced with low
volume fraction of particles tend to settle faster particularly
if the melt temp is high.
S.Balasivanandha Prabu, L.Karunamoorthy,
S.Kathiresan, B.Mohanb et. al. [9] fabricated A384
aluminium alloy with stirring speeds have been taken as
500, 600 and 700 rpm and the stirring times taken were 5,
10 and 15 min for this study. and results revealed that
stirring speed and stirring time influenced the
microstructure and the hardness of composite. From the
microstructure analysis, it has been found that during lower
speed and lower stir time particle clustering occurred in
some places, and some places were identified without SiC
inclusion. By increasing the stirring speed and stirring time
better homogeneous distribution of SiC in the Al matrix
were found. Better distributions of SiC were found at 600
rpm and 10 min stirring time condition. It was found from
the hardness test.
J. Hashim, L. Loony, M.S.J. Hashmi et. al. [10] mechanical
stirring is necessary to help to promote wettability of SiC
particles in the matrix alloy A356 and magnesium as a
wetting agent. Increasing the volume percentage of SiC
particles in the matrix alloy decrease the wettability. Using
magnesium enhances wettability increasing the contact
above 1 wt. % Mg increases the viscosity of the slurry to the
detriment of particles distribution.
Md. Habibur Rahmana, H. M. Mamun Al Rashedb et.
al.[11] investigated microstructures, vickers hardness,
tensile strength and wear performance of the prepared
composites were analyzed. and get in out form of addition of
SiC in Al matrix increased vickers hardness and tensile
strength of composites. when compared with unreinforced
Al. 20 wt. % SiC content AMC showed maximum hardness
and tensile strength. Wear resistance of SiC reinforced AMCs
showed an increase with increasing SiC content in Al matrix.
20 wt. % SiC reinforced AMC showed maximum wear
resistance.
3. DEVELOPMENT OF Al-SiC MMC
In the present work HE 30 aluminum alloy is taken as
matrix and SiCp (400 mesh size) is selected as
reinforcement. Al-SiC composites were developed through
bottom pouring stir casting process by varying percentage
of weight fraction for SiCp (10 %, 15 %, and 20 %) in melt
aluminum matrix at SwamEquip, Chennai. and then after
Hardness and microstructure of cast sample analyzed.
Table - 1: composition of HE 30 alloy
Element Contain %
Si 0.8
Fe 0.2
Cu 0.03
Mn 0.65
Mg 0.92
Zn 0.039
Ti 0.025
Cr 0.035
Ni 0.005
Al 97.20

3.1 Bottom pouring type stir casting furnace
A special designed furnace in which pouring of melt into the
mould happens from its bottom through a remote control
switch. This type of furnace does not require the user to lift
and pour the melt into the mould.
Fig - 3: Bottom pouring type stir casting furnace [12]
3.2 Fabrication Method
First of initial start the furnace. Ingots of aluminium alloy
(HE 30) were melted at 720ºC and mixing the SiC particles
were preheated at 300ºC for 30 min to make in hot air oven.
Degasser 22 tablet was added during melting of aluminium
alloy and after addition of SiC particles.
The furnace temperature was first raised above the liquids
to melt the alloy ingot completely and was then cooled down
to 600 ºC. the liquids to keep the slurry in a semi-solid state.
At this stage the preheated SiC particles (10 %, 15 %, and 20
%) were added. To overcome wettability problem 1%
magnesium was added in slurry.
After sufficient mixing was done, the composite slurry was
reheated to a fully liquid state and then automatic
mechanical mixing was carried out for 10 minutes at a
stirring rate of 600 rpm. In the final mixing process, the
furnace temperature was controlled within 720 ± 100ºC.
Pouring of the composite slurry has been carried out in
bottom pouring die.
Five Al-SiC stir cast product produced with percentage of
weight fraction of 10, 15, 20 SiC are shown in Table 2.
Table - 2: Experiment Table
N
o
(%
SiC)
SiC in
gm
Al in
gm
Mg in
gm
Shieldin
g gas
(Argon)
Strring
speed
(RPM)
Stirring
time
(minute)
1 10 100 1065 10(1
%)
- 500 10
2 10 150 1500 - 1LPM 600 10
3 20 300 1500 - - 600 10
4 10 150 1500 15(1
%)
- 600 10
5 15 225 1500 15(1
%)
- 600 10
Fig - 4: Cast part
By visual inspection it is observed that SiC particles are not
incorporate in Al-SiC MMC. It might be due to poor
wettability of particles or Settlement of silicon carbide
particle. But 10% of Al-SiC part is faithfully pass in the
hardness test.
4. Hardness test
Theoretically the hardness of the cast part should be
uniform from the top to the bottom. However, other factors
such as cooling rate, gravity effect and non-uniform
distribution of the particles in the cast part will give
different values of hardness. The experimental data shows
the hardness of the cast part.
here show that the hardness of all Al-SiC cast sample is
tested by Vickers hardness testing machine (ASTM E 384).

Chart - 1: Hardness value of cast sample with different
composites
From above chart 1, it is seen that hardness of composite
which reinforced with 10% SiC (S. No 2 & 4) compare to Md.
Habibur Rahman et. al obtained that 42.30 ± 2.43 HV
hardness of Al alloy - 10% SiC (200-270 mesh size). which is
faithfully satisfied compare to present composite result.[10]
5. Microstructure analysis
The microstructure of sample is studied using scanning
electron microscopy analysis (SEM) and it is presented in
Figure 5.
X100 X270
X270 X500
Fig - 5: scanning electron microscopy analysis (SEM) of
cast sample (Al-15% SiCp)
The particles are unevenly distributed macroscopically
(SEM test) in fig 5, because of some particle-free zones due
to particle pushing effects during solidification and some
particle agglomeration.
6. Literature review on Electric discharge
machining
Manish Vishwakarma et. al. [12] reviews the recent
developments and advances in the field of high performance
manufacturing environment using Die Sinking EDM, WEDM,
Dry EDM and RDE-EDM. The review is based on prominent
academic publications researches. EDM process, its working
principle, and basic process parameters are discussed. The
results obtained indicate that Al/SiC MMC is machinable by
using some non-conventional machining processes. The
findings show that EDM process is suitable for machining
particle reinforced metal matrix composite (PRMMCs), but
the process is very slow. The research work focuses mainly
on influence of reinforcement on surface quality of
machined material. So EDM has emerged as the most cost
effective and high precision machining process in past years.
The machining capacity to remove hard and difficult to
machine parts has made EDM as one of the most important
machining processes.
C.Velmurugan,R.Subramanian,S.Thirugnanam,B.Ananad
avel et, al. [13] investigated the effect of parameters like
Current(I), Pulse on time(T), Voltage(V) and Flushing
pressure(P) on metal removal rate (MRR),tool wear
rate(TWR) as well as surface roughness(SR) on the
machining of hybrid Al6061 metal matrix composites
reinforced with 10% SiC and 4%graphite particles.
Composite was fabricated using stir casting process. A
central composite rotatable design was selected for
conducting experiments. Mathematical models were
developed using the MINITAB R14 software. The method of
least squares technique was used to calculate the regression
coefficients and Analysis of Variance (ANOVA) technique
was used to check the significance of the models developed.
Scanning Electron Microscope (SEM) analysis was done to
study the surface characteristics of the machined specimens
and correlated with the models developed. They found that
metal removal rate of the composite increases with increase
in current, pulse on time and flushing pressure of the
dielectric fluid while it decreases with increase in voltage.
Tool wear rate of the developed composite increases with
increase in current and voltage and it decreases with
increase in pulse on time and flushing pressure of the
dielectric fluid. They found that surface roughness of the
composite during electric discharge machining increased
with increase in current, pulse on time, voltage and flushing
pressure.
0
5
10
15
20
25
30
35
40
45
S.
No 1
S.
No 2
S.
No 3
S.
No 4
S.
No 5
Average hardnesss in HV1 test
Average
hardnesss in
HV1 test

Harpreet Singh, Amandeep Singh et, al. [14] EDM is
generally used for machining for those materials which are
cannot processed by conventional machining process. In
this studied we compared the material removal rate
achieved using different tool materials. Workpiece used is
AISI D3 and tool materials used copper and brass electrode
with pulse on/pulse off as parameter. The electrolyte used is
kerosene oil. In case of brass electrode the MRR increases
with the increase in the pulse on-time from 50-100μs. This
may be reason that as the MRR of brass electrode is less as
compare to copper electrode so less debris are produced
which can be easily flushed away in pulse off time of 50μs.
the increase in pulse off time from 15μs to 20μs the MRR
increased for both copper and brass electrodes . At short
pulse off time (15μs) MRR is less due to the fact that with
short pulse off time the probability of arcing is very high,
because the dielectric in the gap between the work piece
and electrode cannot be flushed away properly and the
debris particles still remain in discharge gap and this results
in arcing, due to which MRR decreases. With the increase in
pulse-off time, better flushing of debris take place from the
inter-electrode gap, resulting in increase in MRR.
7. DESIGN OF EXPERIMENT
In the Taguchi method the results of experiments are
analyzed to achieve one or more of the following objectives:
 To establish the best or the optimum condition for a
product or process.
 To estimate the contribution of individual parameters
and interactions.
 To estimate the response under the optimum condition.
The optimum condition is identified by studying the main
effects of each of the parameters. The main effects indicate
the general trends of influence of each parameter. The
knowledge of contribution of individual parameters is a key
in deciding the nature of control to be established on an
EDM process.
7.1 Selection of process parameters
Most researchers identified EDM process parameters that
greatly affect response parameters. Process parameters like
Current, Pulse ON time, Pulse OFF time, Voltage, Flushing
pressure, Duty cycle are most frequently used for research
work. Thus in this study Current (A), Gap voltage (V), and
pulse on time (µs) and Material (% of SiCp) of developed
material taken to identify influential parameter on response
variables like Material removal rate (MRR), Tool wear rate
(TWR), Surface roughness (Ra).
Table - 3: Machining parameters with level value
Sr
no.
Machining
parameter
Level 1 Level 2 Level
3
1 Current
(amp)
5 12 20
2 Gap Voltage
(Volt)
10 20 30
3 Pulse on
time (µs)
100 500 1000
4 Material (%
of SiCp)
10 15 20
Table - 4: Fixed variables
Sr no. Fixed Parameter Set value
1 Pulse off time (µs) 50
2 Tool Electrode Copper
3 Dielectric fluid Kerosene + oil
As per table 5, L27 orthogonal arrey of "Taguchi method"
has been selected for experiment design in MINITAB 17.
Table - 5: Experiment Design of L27
Sr
No.
Current
(amp)
Gap
voltage
(v)
Pulse
on
time
(µs)
Material
(% of SiCp)
1 5 10 100 10
2 5 10 100 10
3 5 10 100 10
4 5 20 500 15
5 5 20 500 15
6 5 20 500 15
7 5 30 1000 20
8 5 30 1000 20
9 5 30 1000 20
10 12 10 500 20
11 12 10 500 20
12 12 10 500 20
13 12 20 1000 10
14 12 20 1000 10
15 12 20 1000 10
16 12 30 100 15
17 12 30 100 15
18 12 30 100 15
19 20 10 1000 15
20 20 10 1000 15
21 20 10 1000 15
22 20 20 100 20
23 20 20 100 20
24 20 20 100 20
25 20 30 500 10
26 20 30 500 10
27 20 30 500 10

7.2 Response variables evaluation
Metal removal rate (MRR) is expressed as the ratio of the
difference of weight of the work piece before and after
machining to the machining time, i.e.
MRR = Wjb - Wja g/min
T
Where, Wjb and Wja are the weights of the work piece
before and after machining, and T is the machining time.
Tool wear rate (TWR) is expressed as the ratio of the
difference of weight of the tool before and after machining to
the machining time, i.e.
TWR = Wtb - Wta g/min
T
Where, Wtb and Wta are the weights of the tool before and
after machining and T is the machining time. [13]
Surface roughness (SR) of the machined work piece is
evaluated using a Mitutoyo talysurf tester SJ-210 with a
diamond stylus tip.
Table 6, shows the result in terms of response variables as a
MRR, TWR and SR values for all 27 experiments.
Table - 6: L27 Experiment data
Sr
No
.
Current
(amp)
Gap
voltag
e (v)
Pulse
on time
(µs)
Material
(% of
SiCp)
MRR
(g/
min)
TWR
(g/
min)
SR
(µm)
1 5 10 100 10 0.016 0.007 3.46
2 5 10 100 10 0.015 0.006 3.16
3 5 10 100 10 0.016 0.007 3.52
4 5 20 500 15 0.021 0.009 5.16
5 5 20 500 15 0.021 0.009 4.78
6 5 20 500 15 0.020 0.010 4.37
7 5 30 1000 20 0.031 0.012 6.45
8 5 30 1000 20 0.032 0.011 6.52
9 5 30 1000 20 0.033 0.010 6.53
10 12 10 500 20 0.034 0.012 10.93
11 12 10 500 20 0.033 0.013 10.29
12 12 10 500 20 0.034 0.012 11.45
13 12 20 1000 10 0.037 0.009 11.21
14 12 20 1000 10 0.037 0.010 11.22
15 12 20 1000 10 0.036 0.012 11.22
16 12 30 100 15 0.033 0.016 7.17
17 12 30 100 15 0.035 0.014 7.06
18 12 30 100 15 0.034 0.015 6.72
19 20 10 1000 15 0.048 0.018 12.25
20 20 10 1000 15 0.050 0.016 13.76
21 20 10 1000 15 0.052 0.014 13.70
22 20 20 100 20 0.046 0.020 11.96
23 20 20 100 20 0.043 0.023 11.53
24 20 20 100 20 0.044 0.022 11.68
25 20 30 500 10 0.042 0.019 8.54
26 20 30 500 10 0.041 0.020 8.54
27 20 30 500 10 0.043 0.018 8.37
8. Anova analysis
The experimental results obtained are plotted for main
effect on MRR, TWR, SR.
 Main effect plots for MRR
Fig - 6: Graph of input parameters v/s Material removal rate
In EDM process the impact of different machining
parameters likes current, pulse on time, gap voltage and
material has significant impact on MRR, as shown in above
the figure 6.
In this work, Current is relatively depend on MRR in the
range of 5A to 20A. This is expected way to outcome
because when increase in pulse on time then current
produced strong spark. which produced higher temperature
at that time moreover material to melted and removed from
the work piece. Apart from it is clearly seen that the another
factors does not affect more then compared to current.
when increase the current from 5A to 20A material removal
rate increased. But MRR decreased monotonically with the
increase in pulse on time. In this experiment gap voltage has
no more significant effect shown on MRR because of the
value of gap voltage taken is 10V, 20V, 30V.
It is well known truth that the spark energy increases with
pulse on time. MRR generally starts to decrease when the
value of pulse on time increase up to maximum limit. This
was due to higher pulse on time, the plasma produced
between inter electrode gap in reality hinder transferred
energy and thus reduced MMR.
And the material has been used in EDM process it is shown
that %SiCp is increase than MMR is also increase, because of
the reinforcement is added by weight of percentage then
material become more harder so the that effect on the MMR
it shown.
 MRR is 20 Amp (current), 30 volt (Gap Voltage),
1000 µs (pulse on time), 20 %SiCp (Material). it is observed

from the graphs and obtained that it is optimum value of
MRR.
 Main effect plots for TWR
Fig - 7: Graph of input parameters v/s Tool wear rate
parameters likes current, gap voltage, pulse on time and
material has significant impact on TWR as shown in above
figure 7.
When current increase then pulse energy also increase and
therefore additional heat energy has been produced in the
tool work piece, leading to increase in melting and
evaporation of the electrode.
Current is directly impact on TWR and pulse on time is
relatively to reduced tool wear rate.
 5 Amp (current), 10 volt (Gap Voltage), 1000 µs
(pulse on time), 10 %SiCp (Material). it is observed from the
graphs and obtained that it is optimum small value of TWR.
 Main effects plots for SR
Fig - 8: Graph of selected process parameters v/s Surface
roughness
parameters likes current, gap voltage, pulse on time and
material has significant impact on SR, as shown in above
figure 8.
In this work, Current is relatively depend on MRR in the
range of 5A to 20A. it is expected way to outcome because
when increase in pulse on time then current produces
strong spark. which produced creation a bigger crater at the
place of discharge and therefore rougher surface is
produced. Apart from it is clear that the other factor does
not influence much as compared to current.
Related trends of surface roughness are obtained through
the increase of pulse on time and with increase in gap
voltage SR decrease as shown in figure 8.
 5 Amp (current), 30 volt (Gap Voltage), 100 µs
(pulse on time), 10 %SiCp (Material). it is observed from the
graphs and obtained that it is best surface finish value of SR.
8. CONCLUSION
In the present work the preparation of Al-SiC metal matrix
composite through bottom pouring stir casting and the
parametric analysis on Electrical discharge machining of
MMC. A taguchi design and Anova analysis method is
proposed to find the optimal setting of process parameters
to give better machining characteristic. From the project
work following conclusions can be drawn, based on the
experimental results.
 Bottom pouring stir casting technique could not be
successfully developed with 15 and 20 percentages of SiC
reinforcement caused with poor distribution of SiC particles
in the metal matrix composite (MMC).
 During experimentation work it observed that the
porosity in aluminium - silicon carbide (Al-SiC) composite is
increased with from 10 to 15 and 20 volume fraction of SiC
reinforced particles in Aluminium matrix.
 It has been seen that higher hardness value in which
reinforcement with 10 percentage SiC composite is
39.33HV1 compare to 15 and 20 percentage are 32.33 and
34.67HV1 respectively.
 In scanning electron microscopy analysis particles are
unevenly distributed in 15 percentage of SiC in Al-SiC
composite.
 Based on the conducted experimentation of Al-SiC MMC
were used 10, 15, 20 percentage of SiC reinforced, but highly
recommend that must not go after 10 percentage of SiC for
MMC, because of it is not given the better result.

 From the Anova analysis find that for MRR, current was
the most influential factor and then pulse on time. MRR
increased 0.023 to 0.048 g/min with the current from 5A to
20A and as the pulse on time extended after certain limit
then MRR decreased monotonically.
 In tool wear rate, current 5A to 20A has a significant
direct effect on TWR and pulse on time 100µs to 1000µs is
relative to reduce 0.015 to 0.012 g/min for the tool wear
rate. gap voltage has no much more major effect shown on
TWR because of it range is to smaller.
 About Surface roughness(SR), the most important factor
was current but during experiment observed that at 10 gap
voltage creation a bigger crater at the place of discharge and
therefore rougher surface is produced. while increased
pulse on time 100µs to 1000µs effect on SR increased 7.06
µm to 13.76 µm was observed.
REFERENCES
[1] L.M. Manocha and A.R. Bunsell, “Advances in
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[2] Berghezan, Non-ferrous Materials, Nucleus, 8(5)
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[11] http://www.swamequip.in/swamequip-products---
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Using Copper And Brass Electrode In EDM”
International Journal of Engineering and Science ISSN:
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IRJET- Development of Al-Sic MMC by Bottom Pouring Stir Casting and Parametric Analysis on EDM

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